GEAR PUMP Serie WPP, WPL - Tapflo · 2020-03-18 · Pompa ad Ingranaggi - Serie WPP, WPL Gear Pump - WPP, WPL Series 26 1.4 NAME, TYPE The pump standard execution is that with brass

Serie WPP, WPL

GEAR PUMP

OPERATING AND MAINTENANCE MANUAL

POMPE CUCCHI s.r.l.

POMPE CUCCHI s.r.l. 20090 Opera (MI) - ITALY Via dei Pioppi, 39

Tel.(+39) 02 57606287 (R.A.) Fax (+39) 02 57602257 e-mail: [email protected]

Pompa ad Ingranaggi - Serie WPP, WPL Gear Pump - WPP, WPL Series

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CONTENTS

1. GENERAL INFORMATION .........................................................................................................25

1.1 SUPPLY CONDITIONS...................................................................................................25 1.2 MANUFACTURER..........................................................................................................25 1.3 USER MANUAL CONTENT ............................................................................................25 1.4 NAME, TYPE ..................................................................................................................26 1.5 NOISE EMISSIONS........................................................................................................26 1.6 APPLICATION FIELDS AND LIMITS. ALLOWED AND NOT ALLOWED USES..............26

2. TRANSPORT, HANDLING, PACKAGING, STORAGE...............................................................27

3. DESCRIPTION OF THE PUMP AND THE PUMP UNIT.........................................................................27

3.1 GENERAL DESCRIPTION OF THE MACHINE...............................................................27 3.2 WARNINGS ....................................................................................................................27 3.3 PROTECTION DEVICE ..................................................................................................28 3.4 ADDITIONAL DESCRIPTION OF ACCESSORIES .........................................................28

3.4.1 Seal parts............................................................................................................28 3.4.2 Safety valve ........................................................................................................28

4. INSTALLATION, ASSEMBLY.....................................................................................................29

4.1 SPECIAL ASSEMBLY TOOLS........................................................................................29 4.2 INSTALLATION SITE INFORMATION ............................................................................29

4.2.1 Space requirements for operation and installation...............................................29 4.2.2 Inspection before starting installation ..................................................................29 4.2.3 Foundation details...............................................................................................29 4.2.4 Alignment requirements ......................................................................................29 4.2.5 Suction lift ...........................................................................................................29

4.3 INITIAL INSTALLATION..................................................................................................31 4.3.1 Complete Pump Unit ...........................................................................................31 4.3.2 Free shaft pump..................................................................................................31

4.4 DRIVE UNIT AND ACCESSORY ASSEMBLY ................................................................32 4.4.1 Motor ..................................................................................................................32 4.4.2 Installation of safety and control devices .............................................................32

4.5 ELECTRICAL CONNECTIONS, CONNECTION CABLES ..............................................32 4.6 PIPING............................................................................................................................32

4.6.1 General ...............................................................................................................32 4.6.2 Forces and moments which operate on suction and delivery flanges. .................32 4.6.3 Fastening screw torques .....................................................................................33

5. COMMISSIONING, OPERATION, SHUTDOWN .........................................................................33

5.1 DOCUMENTATION ........................................................................................................33 5.2 PUMP PREPARATION FOR STARTUP .........................................................................33

5.2.1 Filling / discharge ................................................................................................33


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5.2.2 Electrical connections .........................................................................................33 5.2.3 Verifying the direction of rotation .........................................................................33

5.3 SAFETY DEVICES .........................................................................................................33 5.3.1 Mechanical safety devices (guards for rotating parts)..........................................33 5.3.2 Acoustic insulation ..............................................................................................34 5.3.3 Splash-proof cover ..............................................................................................34 5.3.4 Regulation on the electric components................................................................34

5.4 COMMISSIONING ..........................................................................................................34 5.4.1 Initial commissioning ...........................................................................................34 5.4.2 Startup after shutdowns ......................................................................................34 5.4.3 Pump system requirements.................................................................................35 5.4.4 Startup/shutdown frequency................................................................................35 5.4.5 Operation and startup with closed valve ..............................................................35

5.5 SHUTDOWN...................................................................................................................35 5.5.1 Decommissioning................................................................................................35 5.5.2 Emptying.............................................................................................................35

6. MAINTENANCE AND INSPECTION...........................................................................................35

6.1 USE PRECAUTIONS......................................................................................................35 6.2 WEARABLE MATERIALS ...............................................................................................36 6.3 SURVEILLANCE DURING OPERATION ........................................................................36 6.4 PREVENTIVE MAINTENANCE.......................................................................................36 6.5 PUMP DISASSEMBLY AND REASSEMBLY ..................................................................36

6.5.1 Tools...................................................................................................................36 6.5.2 Disassembly/reassembly procedure....................................................................36

7. FAULTS: CAUSES AND SOLUTIONS .......................................................................................40

8. WARRANTY CONDITIONS ........................................................................................................42

9. ALLEGATI/ANNEXES ................................................................................................................43


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1. GENERAL INFORMATION

1.1 SUPPLY CONDITIONS According to agreements with the Customer, the pump can be supplied either as bare shaft or pump unit. By pump unit we mean the pump coupled with the motor, including reduction gears and/or speed variators, if any. The coupling can be direct (WPP series, only for bare shaft pumps) or through bell housing (WPL series).

1.2 MANUFACTURER The pump Manufacturer is POMPE CUCCHI S.R.L.. You can apply for assistance by send-ing a request to the following address:

Via dei Pioppi 39 - 20090 OPERA (MI) ITALY Tel. +39.02.57.60.62.87 (Hunting Line) Fax +39.02.57.60.22.57 E-mail : [email protected]

1.3 USER MANUAL CONTENT This user manual provides all the necessary information to ensure a safe and correct use of the machine. It was written – when applicable – according to point 5.5 of Standard EN 292 part 2-1992 - Machinery Safety; according to point 7 of Standard UNI EN 809-2000 Pumps and Pump Units for Liquids - Common Safety Requirements - and according to point 1.7.4 of Directive 98/37/EC 1998 (ex 89/392 EC). In this manual it is constantly referred to safety in-structions. Such instructions are identified by the following symbols:

It represents the safety instructions contained in this manual, whose non-observance may compromise safety.

It is shown when electrical safety is essential to worker protection.

It indicates the safety instructions which should be taken into ac-count for the safe operation of either the pump, the pump unit or the pump or pump unit protection.


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1.4 NAME, TYPE The pump standard execution is that with brass body, AISI 316 shafts, AISI 316L gears and shafts, bearing bushes in graphite and ceramic/graphite/NBR mechanic seal. The complete series covers different executions (AISI 316 body, gears in KK plastic) and different capaci-ties. Moreover, executions with special mechanic seal or magnetic drive are also provided. The pump identification is realized through an alphanumeric code (see the following exam-ple): - 0WLZ008/NZPFB00: pump type WPLZ, brass execution, rated capacity 8 l/min. at 1500

rpm (displacement 6,2 cm3/rev), shafts made of stainless steel, a gear in KK plastic, stan-dard mechanic seal, equipped with brass safety valve, with bell housing for coupling with a Size 80 motor.

1.5 NOISE EMISSIONS - Reference standard: CEN/TC 197/SC3 N 21 E -fig.8- ISO 3744 on 6 positions - Measured values:

1 - Equivalent weighted continuous acoustic pressure level Leq = 80 dB(A); 2 - Maximum weighted instantaneous acoustic pressure C (peak level) Lpc < 82 dB(C).

- Test conditions: When measuring noise, the pumped liquid (ref. to oil with 30 cP viscosity) must be introduced into the testing system at a speed of less than 0.8 m/s into pipes. It must however reach laminar flow regime (thus the speed must be related to the viscosity) and the conditions outlined in this manual must be respected.

1.6 APPLICATION FIELDS AND LIMITS. ALLOWED AND NOT ALLOWED USES Each machine shall be used according to the type of application, operating conditions and liquid characteristics provided in contract specifications. Each variation which alters the in-tended use of the pump is forbidden and the User is fully responsible for it (e.g. the use of a liquid which is corrosive to pump materials rather than the recommended fluid, etc.). For variations in use within the application limits (e.g. fluid viscosity variations) it is advised to contact the Manufacturer in advance. The maximum operating pressure, for pumps in standard execution, is of 15 bar. In any case, the use of “KK” or alike plastic gears to allow the pump to operate also with poorly lubricating fluids, requires greater attention to avoid excessive or unex-pected pressure loads. It is absolutely forbidden to use the machine in hazardous environments (explosive atmosphere, etc…), the use of hazardous substances (e.g. fluids with dangerous gases), in critical conditions (e.g. abnormal temperatures, etc…), which are not sup-plied with the pump. For pumps and pump units intended to be used in potentially explosive environ-ments, please read carefully “Additional instructions for the operation and manage-ment of pumps and pump units intended to be used in potentially explosive atmos-pheres (Directive 94/9/EC)”. In case of slipping of the magnetic coupling, the surface temperature can reach 350°C in a few seconds; therefore, it is necessary to provide a continuous monitoring of the temperature near the coupling. Pompe Cucchi S.r.l. declines every responsibility for the consequences arising from an im-proper use of the machine which does not comply with what prescribed in this manual or specifically requested when ordering.


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2. TRANSPORT, HANDLING, PACKAGING, STORAGE

Pompe Cucchi sells “ex works”. Consequently, transport from the manufacturing shop to the named place of destination is carried out by the Customer under his own responsibility. For each transport a suitable standard packaging is ensured or established based on Customer requirements who, in any case, must give information about the type of shipment to be per-formed (by land, air, “overseas“). In case of long stationary periods under critical environmental conditions (such as: high hu-midity and/or salinity, etc.) the supply shall be stored in a protected environment.

3. DESCRIPTION OF THE PUMP AND THE PUMP UNIT

3.1 GENERAL DESCRIPTION OF THE MACHINE Essentially the pump consists of two driven pinions which mesh one another inside a cast main body, thus creating a flow of liquid between the inlet and the outlet.

The fluid containment inside the pump is ensured by a suitable seal part as defined in the order. Pumps, series WPL are connected to the motor (shape B34), according to CE standards, by means of a flexible (or magnetic) coupling and a bell housing, which also acts as safety coupling guard. The pump unit series WPL can be equipped with a mechanic reduction gear or a hydraulic variator to adjust the rotation speed, according to CE standards.

3.2 WARNINGS Standard construction pumps, as an indication, require a NPSH of approx. 0.4 bar. Always calculate the maximum available suction lift, in relation to fluid characteristics, suction circuit and operating conditions. Ensure that gears do not operate when dry. Before starting the pump for the first time or after long stationary periods, it is advisable to fill the gear spaces with oil or liquid being pumped through one of the nozzles and rotate the driving shaft by op-erating manually with a screwdriver on the motor cooling fan. This also makes it possible to check for even and smooth movement of rotary components and excessive friction. It is rec-ommended that an overland cut-out set at approx. 10% above the motor current be installed in the control circuit.

INLET OUTLET


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In our pumps the direction of rotation is clearly shown by an arrow marking the right direc-tion. The pump operating temperature in normal working conditions is about 80°C. In special pump versions, working temperatures of 180°C and more may be achieved. To protect per-sonnel from dangers due to the temperatures reached during the operation of the machine, in the event of accidental contact (burn), the User must reduce the external pump tempera-ture by means of insulation plates, coatings, screens, barriers, etc. As limit reference tem-perature for the contact surface it is advisable to take 55°C. Below this value, for hot smooth surfaces in bare metal, there is no burn threshold. For a detailed knowledge of this problem in relation to different particular cases, the User can read the standard UNI EN 563 Ed.’94, where burn thresholds are specified for several types of surface according to the “surface temperature - contact time” parameters. Liquids to be pumped must not contain abrasive or solid suspension as this will greatly re-duce the pump life. At this purpose we recommend the installation of a properly sized filter on the suction line if solids may be present. When pumps are installed in parallel, the suction lines should be adequately separated to prevent unnecessary turbulence.

3.3 PROTECTION DEVICE The bell housing installed by the Manufacturer is made of an aluminium die-casting, fas-tened to the motor by screws, duly shaped to prevent fingers from coming into contact with moving parts. It can be removed only by using a proper tool.

3.4 ADDITIONAL DESCRIPTION OF ACCESSORIES

3.4.1 Seal parts The pump is usually supplied equipped with mechanical seal. If the Customer requires a particular type of seal, Pompe Cucchi S.r.l. installs the desired seal after verifying if its di-mensions are compatible with those of the pump. In case the Customer requires only the seal mark, the Company leaves the Manufacturer to select the type of seal, by giving infor-mation about the pumped liquid.

3.4.2 Safety valve The pump can be equipped with a safety valve, with adjustable calibration, installed on the front of the pump body. After reaching the calibration pressure, prevailing on the contrast spring reaction, the valve starts opening by connecting the outlet side and the inlet side of the pump. The valve function is just to protect the pump from accidental pressure peaks. Its prolonged opening may imply the pump damaging.


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4. INSTALLATION, ASSEMBLY

4.1 SPECIAL ASSEMBLY TOOLS To assemble the pump you do not need special tools, except for seal extractors (see Main-tenance).

4.2 INSTALLATION SITE INFORMATION

4.2.1 Space requirements for operation and installation The space destined by the Customer to the installation of the machine should be enough to gain access to, install and maintain the pump unit.

4.2.2 Inspection before starting installation Before installation, the Customer must ensure that the environmental conditions of the se-lected site comply with requirements specified under the contract. In particular, unless expressly required and accepted in the order, the installation site should not be exposed to the following environmental conditions: - abnormal temperature; - high humidity; - corrosive atmosphere; - explosion and/or fire hazard areas; - dust, sandstorms; - earthquakes and other similar external conditions; - high level of vibrations; - high altitude; - flood hazard areas.

4.2.3 Foundation details When the pump unit is installed, it shall be firmly fixed in place by fastening bolts or by using other securing methods. Ground fastening bolts or other securing methods shall be of sufficient strength to prevent the pump unit from moving accidentally.

4.2.4 Alignment requirements The alignment operation must not submit the pump unit to axial and radial stress, therefore the offset must always be lower than the tolerance limits expected for the coupling. Particular attention should be paid to the alignment of the assemblies equipped with a mag-netic coupling.

4.2.5 Suction lift The suction lift, that is the vertical distance between the pump inlet mid-point and the free surface of the tank to which the pump is attached, must not exceed 5 m to allow pump prim-ing and avoid cavitation phenomena.


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Otherwise, contact our Technical Department.

Each pump must have its own suction pipe; the installation of two or more pumps with a common suction pipe length causes the pump to work less efficiently. The length of the suction pipe must be reduced as much as possible to minimize pressure losses in such segment; higher pressure losses in the discharge line do not adversely affect the correct operation of the pump (if they do not exceed the delivery limits stamped on rating plate).

Furthermore, it is necessary to check that siphons are not created in the suction pipe, since the formation of air pockets generates vibrations and stresses which are not compatible with the correct operation of the pump and may obstruct the pump priming at startup.

In case of installation below head, the pump does not ensure to be able to intercept the flow of fluid as a shut-off cock or a proper stop valve.

NO YES

NO YES


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4.3 INITIAL INSTALLATION According to the conditions of supply, the pump can be delivered as follows:

4.3.1 Complete Pump Unit In this case the Customer must stiffly fasten the pump unit in order to ensure the correct axis alignment in all operating conditions. We recommend the use of vibration dampers below the motor feet and vibration damping sections on pipes near pump inlets. Once the pump unit has been positioned, proceed as described below: a) connect suction and discharge pipes respectively to the pump inlet and outlet; b) power the motor, by carefully controlling the compatibility of motor voltage and frequency with those

of the system; c) open the intake and discharge pipe valves, if any; d) run the motor for a while to verify that the pump rotates in the direction indicated by the arrow

stamped on the pump.

4.3.2 Bare shaft pump In this case, before following the steps described at Paragraph 4.3.1, choose the type of mo-tor and align it to the pump. The motor must be selected by the Customer depending on the type of operation for which it is specifically requested (continuous operation, discontinuous operation, repeated startups, indoor or outdoor installation, explosive atmosphere, critical environmental conditions, alti-tude, etc.) with power compatible with that required by the pump. Motor and pump shafts are coupled by flexible or magnetic coupling. The aluminium bell housing, with centerings both on pump and motor, guarantees a correct alignment. In case of connection by magnetic coupling it is very important to avoid the generation of ax-ial loads on the inner magnet, which can cause the premature wear of the bush shim ad-justments, by leaving the outer magnet free to position itself axially. After connecting the pump to the engine by the lantern, unscrew the fixing pin of the outer magnet on the crank-shaft and retighten this last after the magnet has reached its balance position. While centering the outer magnet, pay special attention to the effects of the magnetic pull force; in particular beware of fingers (always use safety gloves). Be careful not to damage magnets by accidental shocks. You are recommended to use tools in non-magnetic material.


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4.4 DRIVE UNIT AND ACCESSORY ASSEMBLY

4.4.1 Motor The Company installs EC approved electric motors, of power compatible with that required by the pump, selected according to the desired operating conditions and environmental characteristics. In particular if the pump unit is required to operate in explosive atmosphere, the motor is chosen in explosion-proof execution (we remind that, to be used within the European Union, also the execution of the pump and the relevant fittings must com-ply with directive 94/9/EC).

4.4.2 Installation of safety and control devices If specifically requested in the order form, the Company provides the relief valve, which must be calibrated to protect the pump from damage. Once it has been properly calibrated, the valve must not be tampered with in any way, since volumetric pumps can reach quickly, with the delivery closed, extremely high pressure values, with consequent very serious danger. Any pressure adjustment shall be compulsorily made with the pump stopped and de-pressurized. The User shall install a pressure gauge in the pump outlet; it is advisable to install a vacuum gauge near the pump inlet. In case also a regulating valve is installed on the system, make sure that the calibration pressure differs considerably from the safety pressure not to generate dangerous resonance phenomena (pipe and/or valve break).

4.5 ELECTRICAL CONNECTIONS, CONNECTION CABLES The machine shall be connected to the external ground protection system by the appropriate terminal, which must be identified by the PE letter. Connection cables shall be properly sized and insulated. Before energizing the machine, always verify that the mains voltage and fre-quency are compatible with those of the motor.

4.6 PIPING

4.6.1 General Pipes shall have a suitable diameter to allow a regular flow with low pressure losses. There-fore, we recommend to use, at least for the suction line, pipes with inner diameter equal to or greater than that of the pump inlet, mostly when the viscosity level becomes considerable. To minimize pressure losses in the circuit, we recommend to avoid, as much as possible, abrupt variations of section and direction (curves) along the pipe run, particularly in the suc-tion line.

4.6.2 Forces and moments which operate on suction and delivery flanges. As general rule it would be necessary to interpose flexible vibration damping sections be-tween the pump and the system piping; therefore, we recommend to verify that the flanges of the connection pipes are always placed, in free position, with the planes parallel to those of the flanges of the suction and delivery nozzles to avoid that, after fastening them, forces and moments of excessive value are generated. In any case, the User shall make sure that the loads induced on the pump flanges, under the most critical operating conditions, do not exceed the values prescribed by Standards UNI EN ISO 14847.


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4.6.3 Fastening screw torques The fastening torque for the screws of our pumps shall be: - for M6 screws 11-12 Nm - for M8 screws 20-22 Nm - for M10 screws 38-40 Nm For more detailed information, contact our Technical Department.

5. COMMISSIONING, OPERATION, SHUTDOWN

5.1 DOCUMENTATION Operating and maintenance manual

5.2 PUMP PREPARATION FOR STARTUP

5.2.1 Filling / discharge To prevent gears from running dry, before starting the pump for the first time or after long stationary periods it is advisable to fill the gear spaces with oil or liquid being pumped through one of the nozzles and rotate the driving shaft by operating manually with a screw-driver on the motor cooling fan. This also makes it possible to check for even and smooth movement of rotary components and excessive friction. The pump discharge, in case of toxic, noxious or, in any case, dangerous fluid, shall take place according to all the necessary cautions. In particular, the pump body shall be emptied according to proper operating maneuvers.

5.2.2 Electrical connections It is necessary to choose wires which satisfy the operating conditions required by the Cus-tomer (e.g. voltage, current, electric shock protection, bundle of cables) and can support ex-ternal influences (e.g. ambient temperature, presence of water or corrosive substances, me-chanical stresses, fire hazards). Moreover, we remind that wires must be properly sized to ensure the voltage drop from the power supply inlet to the point of load application does not exceed 4%.

5.2.3 Verifying the direction of rotation Open the intake and discharge valves. To verify the direction of rotation run the motor for a while only to check that the pump rotates in the direction marked by the arrows.

5.3 SAFETY DEVICES

5.3.1 Mechanical safety devices (guards for rotating parts) The hazardous area, represented by the projecting sections of pump side and motor side shafts and the coupling, shall be protected against accidental contact using bell housing, which must be firmly secured both to the motor and to the pump.


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5.3.2 Acoustic insulation Sound emission values are specified in this manual. The User should always verify if the regulations of his own country prescribe, in relation to the frequency of exposure to emission values, the use of individual protection devices. If it is, he must comply with the require-ments contained in the above-mentioned regulations to protect the operator’s health and safety.

5.3.3 Splash-proof cover In the event the liquid being pumped is dangerous, the operator must be in any case pro-tected against the risk of any accidental contact with jets of liquid by wearing appropriate in-dividual protection devices.

5.3.4 Regulation on the electric components We remind that in accordance with Standard EN 60204-1 Ed1998-04, as power disconnect-ing switch, a plug/socket combination is allowed for a machine with rated power equal to or lower than 16 A and a total power equal to or lower than 3 kW.

5.4 COMMISSIONING

5.4.1 Initial commissioning - Ensure that the pump unit is properly earthed. - Verify that suction pipes are properly joined one another to avoid air infiltrations which

would prevent the pump from priming. - Check that siphons are not created in the suction pipes so that pump can completely re-

move the air. In this case, if the air is not completely removed then the flow rate may de-crease and the noise level may increase although the pump has taken in the liquid, with consequent premature deterioration of bearing bushes and moving parts.

- Verify the proper operation of the relief valve; to do so it is necessary to gradually increase pressure, by acting on the valve located on the discharge pipe, up to reach the expected calibration value. Now, after a further rotation of the valve, the discharge pressure shall remain lower than the calibration value. Otherwise, after stopping the machine and de-pressurizing the pump, it is necessary to disassemble the valve cap 31, remove the gasket below 30, loosen the nut 29and rotate counterclockwise the spring 17 pre-load ad-justing ring nut 30 (clockwise to increase the pre-load). Retighten the lock nut 29, inter-pose the gasket 30 and rescrew the protection cap 31. The adjusting ring nut 30 is not equipped with retainer, therefore it is necessary to pay attention, when unscrewing it, not to cause a leakage of the fluid being pumped.

5.4.2 Startup after shutdowns The most common case in which the pump may stop working - apart from the power supply failure (black out) – is when the electric motor overcharge protection comes into operation. In this case, before starting the pump examine the causes which triggered the activation of the protection and remove them. In magnet drive pumps, it may happen that, when the maximum torque value that can be transmitted is exceeded, the pump stops while the engine runs idle. In this case you need to stop immediately the engine, wait until the magnet “bell” of the inner magnet is cooled (the heating of this last is due to the effect of eddy currents), and restart the engine after eliminat-ing the causes of the failure.


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5.4.3 Pump system requirements In volumetric pumps, pressure is not related to flow rate and/or rotation speed; therefore, avoid installing shut-off valves on the discharge pipe and, in any case, between the pump and the stop valve a relief valve must always be installed.

5.4.4 Startup/shutdown frequency Pumps which are expressly requested by the Customer to start frequently and repeatedly do not show any problems for this kind of operation.

5.4.5 Operation and startup with closed valve It is forbidden to start the pump with the discharge valve closed: such mistake would cause an abrupt pressure rise above the limit values with consequent seizing.

5.5 SHUTDOWN

5.5.1 Decommissioning In case of decommissioning of the pump unit, it is necessary to disconnect the power supply to make unexpected and accidental startups impossible.

5.5.2 Emptying A pump or a pump unit which operates with a flammable, toxic, corrosive or, in any way, hazardous fluid, or with a liquid at a temperature higher than 55°C, shall be equipped with a device such as a connection pipe, to be provided by the User, to collect and dispose the liquid drained or coming from any possible leakage from the shaft seal or discharged by a pressure relief valve.

6. MAINTENANCE AND INSPECTION

The maintenance and disassembly operations of the pump must be performed only by authorized and specifically trained personnel.

6.1 USE PRECAUTIONS Before performing any maintenance operation, please observe the following safety precau-tions: - Never execute maintenance operations with the pump running. - Cut the power supply to the pump unit. - Wear gloves, glasses, shoes and protective suits adequate to the characteristics of the liq-

uid being pumped. - Wait until the pump is cooled. - Never open the pump unit and/or the relief valve when the pump is pressurized. - Close suction and discharge pipe valves, if any. - Disconnect the pump from suction and discharge pipes, by paying attention to put a col-

lecting basin for the pipe liquid. - Cut the power supply to the motor and disconnect the earth cable. - Unscrew anchoring screws and remove the pump unit. - Disconnect the pump from the motor.


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- Pay special attention to the effects of the magnetic pull force; in particular beware of fingers (always use safety gloves). Be careful not to damage magnets by acci-dental shocks. You are recommended to use tools in non-magnetic material.

- Place a collecting basin for the pump liquid. - Perform the maintenance operation. - Carry out the pump-motor coupling carefully. - Secure the unit by anchoring screws. - Connect the pump to suction and discharge pipes. - Reconnect the power supply to the motor and the earth cable. - Open suction and discharge pipe valves, if any. - Reconnect the power supply to the pump unit.

6.2 WEARABLE MATERIALS The normal wear parts, included as spares in the 2-year warranty are the following: - bearing bushes; - seal parts (mechanical seal, gaskets); - gears; - shafts.

6.3 SURVEILLANCE DURING OPERATION The pump unit does not need the presence of an Operator during the work cycle. It is up to the User to provide or not a periodic surveillance depending on the importance and serious-ness of the operation. The relevant checks shall be aimed to detect abnormal noise, vibra-tion, temperature levels and/or some dripping from the mechanical seals, variations of pres-sure and/or flow rate, etc.

6.4 PREVENTIVE MAINTENANCE It is always advisable, for a reliable and cost-effective operation, to adopt a policy of preven-tive maintenance. The service time specified for wearable component parts in this manual can be used as reference for the first period of operation. Later the user will be able to im-prove the MTBM (Mean Time Between Maintenance) as a result of the acquired experience.

6.5 PUMP DISASSEMBLY AND REASSEMBLY

6.5.1 Tools No special tools are requested, except for seal extractors.

6.5.2 Disassembly/reassembly procedure Before disassembling the pump, it is necessary to perform the operations mentioned at point 4.6.1 "MAINTENANCE AND INSPECTION". Refer to the drawings and nomenclature attached at the end of the manual.


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1) Single seal (see Figure 1) a) Access to the mechanical seal Remove the lantern from the engine, unscrew the fastening pin F and disassemble the cou-pling H. Disassemble the clamp E and disconnect the pump from the lantern J; remove the feather key G from its housing. Remove, by means of the proper pliers, the seeger rings ? housed in the front cover :, ex-tract the ball bearing @ and the gland ring > which houses the stationary ring of the me-chanical seal <A. In this way, it is possible to check the wearing status of the seal contact surfaces. During re-assembly do not pinch the O-ring = housed in the front of the pump body. b) Replacing static seal To remove the static part of the seal <A from the seal cover >, it is necessary to carry out the same operations as item a) and exert a pressure upon the external side of the seal. After placing the seal cover on a plane and greasing the walls to make assembly easier, insert the new static seal with the relevant O-ring; use a pad interposed with a soft bearing to exert the force perpendicularly to the cover. c) Replacing dynamic seal To remove the dynamic part of the seal < it is advisable to use an iron wire bent at 90° at one end to hook the first or the second coil of the seal spring <B. Exert a traction force par-allel to the shaft K, by paying attention not to scratch this last. After greasing the shaft to make assembly easier, insert the new mechanical seal by rotating the spring in the direction opposite to that of the coil; use a pad interposed with soft bearing to press the seal up to make the spring <B rest on the seeger ; provided on the shaft. 2) Magnet coupling (see Figure 2) a) Access to the inner magnet Place a container of suitable capacity under the inner magnet bell; unscrew the Allen screws ` and disassemble the ring ^, the bell a and the O-ring Y. Unscrew the fastening pin 46 and the screw b and disassemble the inner magnet \. On reassembly, pay attention not to pinch the sealing O-rings Y housed in the flange Z. You are recommended to use tools in non-magnetic material.

d) Replacing bearing bushes Carry out the same operations as indicated in items a), b), c), e). To replace the supporting bushes 4 and 4A, break them with a chisel or similar, paying attention not to damage the diameter of the bushing seats. Before inserting the new bushings, clean accurately the seat with alcohol to remove all impurities and wipe them very well. Fit new bushes by spreading a thin layer of glue of “LOCTITE 648” type over their outer diameters, by paying attention that the cut bush and the integer bush match perfectly. First introduce the integer bush and then the other, by letting glue dry for about 10 - 15 minutes. When the operation is over, set to ze-ro the bush shims with the relevant housing covers. If a surfacing feed is not available, you can choose a base plane abraded with fine emery cloth with P80 type grain for rough grind-ing and 400 type grain for finishing. For assembly, follow the instructions at points e), c), b), a). e) Replacing gears and shafts Carry out the same operations as indicated in items a), b), c).Remove the socket head screws B fastening the rear cover 1 and remove it, considering that the operation might be difficult because of the accuracy of shafts and dowel pins C.


38

Draw a reference mark on the main body 9 to avoid reversing base planes on reassembly and remove it together with the 2 O-ring gaskets 7 housed in it; the operation may become difficult for the accuracy of shafts and dowel pins C. Remove the duct shaft 2, remove the locking spring clip 5, remove the duct gear 6A from the shaft and extract the feather key 8; carry out the same operation on the conductor shaft, after disassembling the seeger ring ; in the front side. On reassembly, reverse the procedure, by taking as reference the position of the rear cover, the position of dowel pins and internal drain lines holes and do not pinch the O-rings 7. Tighten the cover "cross" fastening screws B by rotating simultaneously the motor shaft, to avoid differentiated pressures on gears, which might increase frictions. With regard to tight-ening torques, see paragraph 4.6.3. Then carry out operations indicated in items c), a). f) Safety valve replacement Unscrew the cap O and remove the external sealing washer L. Move the nut M and un-screw completely the adjusting ring nut N, paying attention to the thrust exerted by the spring A; disassemble the internal sealing washer L. Remove the spring A with the shutter assembled D. Disassemble the valve seat P and the sealing washer L. During re-assembly check the correct coupling between the shutter D and the seat P and replace all sealing washers L.


39

BLANK PAGE


40

7. FAULTS: CAUSES AND SOLUTIONS

Here below the most common causes of malfunctions in the operation of pumps are shortly listed together with the possible solutions.

SO

LU

TIO

N

Verify

ele

ctr

ical connections a

nd

therm

al pro

tections

Verify

rating a

nd type o

f (s

tar

- delta)

moto

r connection

Reduce t

he invert

er

sta

rt r

am

p

Verify

that shafts r

ota

te f

reely

Revers

e e

lectr

ic m

oto

r connections

Open v

alv

es

Dis

assem

ble

and c

lean the filt

er

Dra

in p

ipes. R

em

ove s

iphons.

Tig

hte

n fittings a

nd fla

nges

Incre

ase t

he p

ipe d

iam

ete

r. R

e-

move a

bru

pt variations o

f section

and d

irection

Pre

heat

the f

luid

. D

ecre

ase t

he

speed o

f ro

tation.

Sta

bili

ze t

he m

ain

s v

oltage

Sta

bili

ze t

he e

lectr

ic c

ircuit

Incre

ase t

he inert

ia o

f th

e h

ydra

ulic

circuit

Dra

in p

ipes. R

em

ove s

iphons.

Tig

hte

n fittings a

nd fla

nges

Incre

ase t

he v

alv

e o

pera

ting p

res-

sure

Repla

ce w

ith f

ree b

all

foot valv

e

CA

US

E

The m

oto

r is

not pow

ere

d

Incorr

ect supply

voltage

Excessiv

e p

ow

er

consum

ption

Mechanic

al lo

ck o

f m

oto

r and/o

r pum

p

shafts

Direction o

f ro

tation r

evers

ed

Valv

es o

n s

uction a

nd/o

r dis

charg

e

pip

es c

losed

Suction filt

er

clo

gged

Pre

sence o

f air in t

he s

uction p

ipe

Hig

h p

ressure

losses in t

he s

uction lin

e

Flu

id t

oo v

iscous

Overv

oltage a

nd/o

r overc

urr

ent

Feedback e

lectr

ic c

ircuit too s

ensitiv

e

Feedback h

ydra

ulic

circuit t

oo s

ensitiv

e

Pre

sence o

f air in p

ipes

Inte

rmitte

nt

openin

g o

f th

e b

y-p

ass

valv

e

Foot valv

e n

ot w

ork

ing p

roperly o

r of

the type w

ith p

late

and s

pring

OR

IGIN

Ele

ctr

ical

Ele

ctr

ical

Ele

ctr

ical

Mechanic

al

Ele

ctr

ical

Hydra

ulic

Hydra

ulic

Hydra

ulic

Hydra

ulic

Hydra

ulic

Ele

ctr

ical

Ele

ctr

ical

Hydra

ulic

Hydra

ulic

Hydra

ulic

Hydra

ulic

FA

UL

T

The p

um

p d

oes n

ot

sta

rt

The p

um

p d

oes n

ot

suck liq

uid

at sta

rtup

Pre

ssure

and/o

r flow

ra

te p

uls

es in t

he

dis

charg

e lin

e


41

SO

LU

TIO

N

Dra

in p

ipes. R

em

ove s

iphons.

Tig

hte

n fittings a

nd fla

nges

Decre

ase p

ressure

losses in the

suction lin

e.

Reduce the s

peed o

f ro

tation. C

hange f

luid

tem

pera

ture

Repla

ce b

all

bearing a

nd/o

r bushes

Decre

ase p

ressure

losses in p

ipes.

Reduce f

luid

vis

cosity

Decre

ase the s

peed o

f ro

tation o

r in

cre

ase t

he flu

id t

em

pera

ture

Incre

ase b

y-p

ass v

alv

e s

pring p

re-

load

Decre

ase p

ressure

losses in the

suction lin

e.

Change flu

id t

em

pera

-tu

re.

Decre

ase s

peed o

f ro

tation.

Incre

ase b

y-p

ass v

alv

e s

pring p

re-

load

Cool th

e flu

id

Grind

rear

cover

Decre

ase the flu

id tem

pera

ture

CA

US

E

Pre

sence o

f air in p

ipes

Cavitation

Ball

bearing a

nd/o

r bush f

ailu

re

Pum

p s

atu

ration

Excessiv

e s

peed o

f ro

tation in r

ela

tion

to t

he f

luid

vis

cosity

By-p

ass v

alv

e o

penin

g

Cavitation

By-p

ass v

alv

e o

penin

g

Friction incre

ase b

y therm

al effect

Gear

shim

adju

stm

ent to

a g

iven c

lear-

ance g

ear

Decre

ase in v

iscosity d

ue t

o the tem

-pera

ture

incre

ase

OR

IGIN

Hydra

ulic

Hydra

ulic

Mechanic

al

Hydra

ulic

Hydra

ulic

Hydra

ulic

Hydra

ulic

Hydra

ulic

Mechanic

al

Mechanic

al

Hydra

ulic

FA

UL

T

The p

um

p is n

ois

y

and v

ibra

tes

The f

low

rate

does

not

incre

ase a

s the

speed o

f ro

tation in-

cre

ases

Pro

gre

ssiv

e r

educ-

tion o

f th

e d

ischarg

e

flow

rate

and/o

r pre

ssure

, w

ith c

on-

sta

nt speed o

f ro

ta-

tion


42

8. WARRANTY CONDITIONS

Pompe Cucchi S.r.l. guarantees that pumps and pump units are free from defects in mate-rial, construction, workmanship and assembly for a period of 12 (twelve) months from the delivery date (specified on the D.D.T.). The Purchaser's warranty is limited to the free replacement of parts, which are recog-nized faulty, by excluding the purchaser's right of requiring the contract cancellation or the price reduction or other damages. Warranty is void in case of misuse or improper use of the pump by the User. The pump shall be used according to what expressly requested in the order or based on the instructions contained in this manual. Any damages resulting from shocks and/or tampering are not covered by this warranty. Warranty does not apply to normal wear parts and damages due to negligence and poor maintenance. For the application of the warranty it is necessary that: - the Customers immediately notifies Pompe Cucchi s.r.l. the trouble he imputes to the

pump; - the pump was not tampered with; - the pump is returned to Pompe Cucchi s.r.l. clean, after removing any trace of the process

fluid and in a proper packaging; - a short description of the fault is provided in writing together with the operating parameters

of the pump or the pump unit; - if required, a chemical analysis or a sample of the process fluid is provided. Pumps which have not been emptied of the process fluid or installations outside the pump unit will not be taken into account. In the event Pompe Cucchi S.r.l. acknowledges the defect under warranty, no charge will be made to the Customer both for the replaced material and the workmanship. The forwarding charges from the Customer to Pompe Cucchi S.r.l. remain to the Sender’s (Customer) account.


43

9. ALLEGATI/ANNEXES

Le operazioni di manutenzione e lo smontaggio della pompa vanno effettuate unica-mente da personale autorizzato e specificamente addestrato.

Maintenance operations and pump disassembly must be performed only by author-ized and specifically trained people.

Figura 1 Figure 1

DE

SC

RIP

TIO

N

Ba

ck c

ove

r

Dri

ve

n s

ha

ft

Bu

sh

Sp

rin

g c

lip

Dri

vin

g g

ea

r

O-R

ing

Ge

ars

fe

ath

er

ke

y

Ce

ntr

al b

od

y

Fro

nt

co

ve

r

Inte

rna

l re

tain

ing

rin

g

Ro

tatin

g r

ing

(m

ech

. se

al)

O-R

ing

Se

al co

ve

r

Exte

rna

l re

tain

ing

rin

g

Ba

ll b

ea

rin

g

Va

lve

sp

rin

g

So

cke

t scre

w

Do

we

l p

in

Va

lve

sh

utt

er

Clip

Gru

b s

cre

w

Fe

ath

er

ke

y

Co

up

ling

(pu

mp

sid

e)

O-R

ing

Be

ll h

ou

sin

g

Dri

vin

g s

ha

ft

Wa

sh

er

Nu

t

Re

gu

latin

g s

cre

w

Ca

p

Va

lve

se

at

Sp

ace

r

Co

up

ling

(m

oto

r sid

e)

Cu

t b

ush

Dri

ve

n g

ear

Sta

tio

na

ry r

ing

(m

ech

. se

al)

Sp

rin

g (

me

ch

. se

al)

Gru

b s

cre

w

DE

SC

RIZ

ION

E

Co

pe

rch

io p

oste

riore

Alb

ero

co

nd

otto

Bo

cco

la

Mo

llett

a

Ing

ran

ag

gio

co

nd

utt

ore

O-R

ing

Lin

gu

ett

a ing

rana

gg

i

Co

rpo

ce

ntr

ale

Co

pe

rch

io a

nte

riore

An

ello

ela

stico

pe

r a

lbe

ri

An

ello

ro

tan

te (

ten.

me

cc.)

O-R

ing

Pre

mite

nu

ta

An

ello

ela

stico

pe

r fo

ri

Cu

scin

ett

o a

sfe

re

Mo

lla v

alv

ola

Vite

T.C

.E.I

.

Sp

ina

di ri

ferim

en

to

Ott

ura

tore

va

lvo

la

Fa

sce

tta

Gra

no

Lin

gu

ett

a

Giu

nto

la

to p

om

pa

O-R

ing

La

nte

rna

Alb

ero

co

nd

utto

re

Ro

nd

ella

Da

do

Gh

iera

di re

go

lazio

ne

Ca

pp

ello

tto

Se

de

va

lvo

la

Sp

azia

tore

Giu

nto

la

to m

oto

re

Bo

cco

la t

ag

liata

Ing

ran

ag

gio

co

nd

ott

o

An

ello

sta

zio

na

rio

(te

n. m

ecc.)

Mo

lla (

ten.

me

cc.)

Gra

no

Q.T

Y

1

1

2

2

1

2

2

1

1

1

1

1

1

2

1

1

4

2

1

1

2

1

1

1

1

1

3

1

1

1

1

1

1

2

1

1

1

1

Part

s lis

t

ITE

M

1

2

4

5

6

7

8

9

:

;

<

=

>

?

@

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

4A

6A

<A

<B

FA

Figura 2 Figure 2

DE

SC

RIP

TIO

N

Fro

nt cover

O-R

ing

Fla

nge

Drivin

g s

haft

Inner

magnet

Gru

b s

cre

w

Rin

g

Socket scre

w

Hexagonal head s

cre

w

Inner

magnet cover

Socket scre

w

Bell

housin

g

Oute

r m

agnet

Gru

b s

cre

w

DE

SC

RIZ

ION

E

Coperc

hio

ante

riore

O-R

ing

Fla

ngia

Alb

ero

conduttore

Magnete

inte

rno

Gra

no

Anello

Vite T

.C.E

.I.

Vite T

.E.

Cam

pana m

agnete

inte

rno

Vite T

.C.E

.I.

Lante

rna

Magnete

este

rno

Gra

no

Q.T

Y

1

2

1

1

1

1

1

4

4

1

1

1

1

1

Part

s lis

t

ITE

M

X

Y

Z

[

\

]

^

_

`

a

b

c

d

e

POMPE CUCCHI S.R.L. Via dei pioppi, n°39, cap 20090, Opera (MI), Italy Tel. +39 02.57.60.62.87 Fax. +39 02.57.60.22.57 http://www.pompecucchi.com e-mail:[email protected]

DICHIARAZIONE DI CONFORMITA’ La POMPE CUCCHI s.r.l. dichiara, sotto la propria esclusiva responsabilità, che i gruppi di pompaggio serie B, F, FM, FT, MG, MX, N, WPP, WPL, CP, CPP, CMP, CM, DMP, AM5 sono conformi a quanto prescritto dalle seguenti Direttive: 98/37/CE, 93/68/CE, 73/23/CE, 89/336/CE.

DECLARATION OF CONFORMITY POMPE CUCCHI s.r.l. declares, under its own responsability, that pumping sets series B, F, FM, FT, MG, MX, N, WPP, WPL, CP, CPP, CMP, CM, DMP, AM5 are in accordance with the following Direc-tives: 98/37/EC, 93/68/EC, 73/23/EC, 89/336/EC. Date POMPE CUCCHI s.r.l. 30/09/2005 Product Manager (Mario Cucchi)

POMPE CUCCHI S.R.L. Via dei pioppi, n°39, cap 20090, Opera (MI), Italy Tel. +39 02.57.60.62.87 Fax. +39 02.57.60.22.57 http://www.pompecucchi.com e-mail:[email protected]

DICHIARAZIONE DI INCORPORAZIONE PER FORNITURA DI POMPE AD ASSE NUDO

La POMPE CUCCHI s.r.l. dichiara, sotto la propria esclusiva responsabilità, che le pompe serie B, F, FM, FT, MG, MX, N, WPP, WPL, CP, CPP, CMP, CM, DMP, AM5 sono conformi per progetto a quan-to prescritto dalla Direttiva 98/37/CE. Esse non possono essere messe in servizio prima che i gruppi di pompaggio siano stati correttamente assemblati e dichiarati conformi alle seguenti Direttive: 98/37/CE, 93/68/CE, 73/23/CE, 89/336/CE.

DECLARATION OF INCORPORATION FOR SUPPLY OF BARE SHAFT PUMPS

POMPE CUCCHI s.r.l. declares, under its own responsability, that pumps series B, F, FM, FT, MG, MX, N, WPP, WPL, CP, CPP, CMP, CM, DMP, AM5 have been designed in accordance with the 98/37/EC Directive. They cannot be put into operation before the pumping sets have been correctly assembled and de-clared in accordance with the following Directives: 98/37/EC, 93/68/EC, 73/23/EC, 89/336/EC.

Date POMPE CUCCHI s.r.l. 30/09/2005 Product Manager (Mario Cucchi)

Edizione : 09/2007 Edition : 09/2007

POMPE CUCCHI s.r.l.

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